|Publication number||US7201329 B2|
|Application number||US 10/835,617|
|Publication date||Apr 10, 2007|
|Filing date||Apr 30, 2004|
|Priority date||Apr 30, 2004|
|Also published as||US7481383, US20050242214, US20070125889, WO2005111408A1|
|Publication number||10835617, 835617, US 7201329 B2, US 7201329B2, US-B2-7201329, US7201329 B2, US7201329B2|
|Inventors||J. Michael Joseph|
|Original Assignee||Siemens Vdo Automotive Corporation|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (66), Non-Patent Citations (1), Referenced by (1), Classifications (13), Legal Events (6)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This invention relates generally to electrically operated fuel injectors of the type that inject volatile liquid fuel into an automotive vehicle internal combustion engine, and in particular the invention relates to a novel thin disc orifice member for such a fuel injector.
It is believed that contemporary fuel injectors must be designed to accommodate a particular engine. The ability to meet stringent tailpipe emission standards for mass-produced automotive vehicles is at least in part attributable to the ability to assure consistency in both shaping and aiming the injection spray or stream, e.g., toward intake valve(s) or into a combustion cylinder. Wall wetting should be avoided.
Because of the large number of different engine models that use multi-point fuel injectors, a large number of unique injectors are needed to provide the desired shaping and aiming of the injection spray or stream for each cylinder of an engine. To accommodate these demands, fuel injectors have heretofore been designed to produce straight streams, bending streams, split streams, and split/bent streams. In fuel injectors utilizing thin disc orifice members, such injection patterns can be created solely by the specific design of the thin disc orifice member. This capability offers the opportunity for meaningful manufacturing economies since other components of the fuel injector are not necessarily required to have a unique design for a particular application, i.e. many other components can be of common design.
Another concern in contemporary fuel injector design is minimizing a volume downstream of a needle/seat sealing perimeter and upstream of the orifice hole(s). As it is used in this disclosure, this volume is known as the “sac” volume. This sac volume is related to the maximum depth or height of a dimpled surface extending from the orifice disc. As a practical matter, the practical limit of dimpling a geometric shape into an orifice disc pre-conditioned with straight orifice holes is the maximum depth or height required to obtain the desired spray angle(s). As the depth of the geometry is increased in order to obtain the large bending and splitting spray angles, the amount of individual hole and dimple distortion also increases and the sac volume may increase to a volume larger than is desired. Notwithstanding the potential increase in sac volume when the orifice disc is dimpled in order to obtain large values of bending and splitting spray angles, the disc material, in extreme cases, may shear between holes or at creases in the geometrical dimple, thereby rendering the orifice disc unsuitable to function as desired, such as, for example, metering fuel flow.
It is believed that a known orifice disc can be formed in the following manner. A flat orifice disc is initially formed with an orifice that extends generally perpendicular to the flat orifice disc, i.e., a “perpendicular” orifice. In order to achieve a bending or splitting angle, i.e., an angle at which the orifice is oriented relative to a longitudinal axis of the fuel injector, the region about the orifice is dimpled—such that the flat orifice disc is no longer generally planar in its entirety but is now provided with a multi-facetted dimple. As the orifice disc is dimpled, the material of the orifice disc is forced to yield plastically to form the multi-facetted dimple. The multi-facetted dimple includes at least two sides extending at a dimpling angle, i.e., the angle at which the planar surface of the facet on which the orifice is disposed thereon is oriented relative to the originally flat surface towards an apex. Since the orifice is located on one of the sides, the orifice is also oriented at a bending angle β. Because the orifice originally extends perpendicularly through the flat surface of the disc, i.e., a “base” plane, a bending angle of the orifice, subsequent to the dimpling, generally approximates the dimpling angle. And depending on the physical properties of the material such as, for example, thickness and yield strength of the material, it is believed that there is an upper limit to the dimpling angle, as too great a dimpling angle can cause the material to shear, rendering the orifice disc structurally unsuitable for its intended purpose.
The present invention provides for an orifice disc with orifices oriented at an angle that is no longer exclusively related to a dimpling angle but is related to both an oblique angle at which the orifice is oriented relative to a base plane of the orifice disc and the dimpling angle. Thus, the present invention provides for a novel form of thin disc orifice members that can enhance the ability to meet different and/or more stringent demands with equivalent or even improved consistency. For example, certain thin disc orifice members according to the invention are well suited for engines in which a single fuel injector is required to direct sprays or stream to one or more intake valve; and thin disc orifice members according to the invention can satisfy difficult installations where space for mounting the fuel injector is severely restricted due to packaging constraints. It is believed that one of the advantages of the invention arises because the metering orifices are located in facetted planar surfaces. This has been found important in providing enhanced flow stability for proper interaction with upstream flow geometries internal to the fuel injector. The presence of a metering orifice in a non-planar surface, such as in a conical dimple, may not be able to consistently achieve the degree of enhanced flow stability that is achieved by its disposition on a facetted planar surface as in the present invention. The particular shape for the indentation that contains the facetted planar surfaces having the metering orifices further characterizes the present invention.
The preferred embodiments of the present invention allow for a desired targeting of fuel spray. The desired targeting of fuel spray is one which is similar to a fuel spray targeting generated by a control case. By virtue of the preferred embodiments, however, a desired spray targeting similar to the spray targeting of the control case can be obtained while providing for a fuel injector that has less sac volume and less material deformation in an orifice disc than that of the control case. Consequently, it is believed that the present invention provides a better control of fuel flow and spray angles by virtue of reduced orifice hole distortion, and reduced likelihood of orifice disc material shearing.
The present invention provides a fuel injector for spray targeting fuel. The fuel injector includes a seat, a movable member, and an orifice disc. The seat includes a passage that extends along a longitudinal axis. The movable member cooperates with the seat to permit and prevent a flow of fuel through the passage. The orifice disc includes first and second surfaces, a peripheral portion, a central portion, and a first orifice. The first surface confronts the seat, and the second surface faces opposite the first surface. The peripheral portion extends parallel to a base plane, and the base plane being disposed generally orthogonal with respect to the longitudinal axis. The central portion being bounded by the peripheral portion and includes first and second planar facets extending from the peripheral portion. The first and second planar facet intersect each other to define a segment extending at a first angle of less than 21 degrees with respect to the base plane. Each of the first and second planar facets extends at a second angle of less than 16 degrees with respect to the base plane. At least one orifice penetrates each of the first and second planar facets and being defined by a first wall coupling the first and second surfaces. The at least one orifice extends along a first orifice axis, and the first orifice axis is oriented with respect to the longitudinal axis by a combination of a first relationship of the planar facet surface with respect to the base plane and a second relationship of the first orifice axis with respect to the planar facet surface so that when the magnetic actuator moves the closure member to the actuated position, a flow of fuel from the orifice disc intersects a virtual plane orthogonal to the longitudinal axis to define a flow pattern having a first portion about a first arcuate sector of about 180 degrees being greater in area than a second portion on a contiguous second sector of about 180 degrees on the virtual plane.
The present invention further provides a method of targeting fuel flow through at least one metering orifice of a fuel injector to a target area contiguous to a virtual plane disposed generally orthogonal to a longitudinal axis extending through the fuel injector. The fuel injector has a passageway extending between an inlet and outlet along the longitudinal axis. The fuel injector includes a seat proximate the outlet, an orifice disc having a perimeter generally perpendicular to the longitudinal axis, and a closure member disposed in the passageway and coupled to a magnetic actuator. When the magnetic actuator is energized, the actuator positions the closure member so as to allow fuel flow through the passageway and past the closure member through the seat aperture. The orifice disc includes first and second surfaces that extend substantially parallel to a base plane and that are spaced along a longitudinal axis extending orthogonal with respect to the base plane. The method can be achieved by locating a plurality of metering orifices oriented at an oblique angle with respect to the longitudinal axis; forming first and second planar surfaces on which the metering orifices are disposed on, the first and second planar surfaces extending from a base portion of the orifice disc at a first angle with respect to the base portion and intersecting each other to form an edge oriented at a bending spray angle with respect to the base portion; flowing fuel through the metering orifices upon actuation of the fuel injector so that a fuel flow path intersecting the virtual plane defines a flow pattern having a plurality of different radii about the longitudinal axis, one of the radii including a maximum radius that, when rotated about the longitudinal axis, defines a circular area larger than the flow area; and orientating the flow pattern about the longitudinal axis so as to adjust a targeting of the flow pattern towards a different portion of the circular area.
The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention.
Seat 138 can include a frustoconical seating surface 138 a that leads from guide member 136 to a central passage 138 b of the seat 138 that, in turn, leads to a dimpled central portion 140 a of orifice disc 140. Guide member 136 includes a central guide opening 136 a for guiding the axial reciprocation of a sealing end 122 a of a closure member assembly 122 and several through-openings 136 b distributed around opening 136 a to provide for fuel to flow into the fuel sac volume discussed earlier. The fuel sac volume is the encased volume downstream of the needle sealing seat perimeter, which is the interface of 122 a and 138 a, and upstream of the metering orifices in the area 140 a.
As shown in
The orifice disc 140, as viewed from outside of the fuel injector in a perspective view of
With reference to
Briefly, the increased bending angle θ can be formed by initially forming an orifice with a suitable tool that is angled to a flat work piece 10 at the orifice angle α, i.e., “angled” orifice, relative to a virtual base plane 150 which is contiguous to at least a portion of disc. That is, the wall 148 a of the orifice 148 is oriented about orifice axis 202, which is contiguous to a plane orthogonal to the base plane 150. Thereafter, the work piece 10 is deformed in a dimpling operation, to form a multi-facetted dimple 143 a at the same dimpling angle δ as in the conventional dimpled disc. As shown in
In the preferred embodiments, the central portion 140 a of orifice disc 140 includes a multi-faceted dimple 142 that is bounded by the central portion 140 a, as shown in
As provided by the preferred embodiments, the dimpled orifice disc 140 provides for an increase in a spray angle θ relative to a longitudinal axis A—A for each of the orifices without increasing the angle at which a facet is oriented relative to the base plane 150, i.e., a bending spray angle β or splitting angle λ (
Prior to the formation of the first facet 143 a, the orifice disc 140 includes first and second surfaces 20, 40 that extend substantially parallel to a base plane 150. The first and second surfaces 20 and 40 are spaced along a longitudinal axis 200. The longitudinal axis 200 extends orthogonally with respect to the base plane 150, as shown in
The preferred embodiments of the orifice disc 140 can be formed by a method as follows. The method includes forming a first orifice 148 penetrating the first and second surfaces 20, 40, respectively, and also includes forming a first planar surface or facet 143 a on which the first orifice 148 is disposed thereon such that the first facet 143 a extends generally parallel to a first plane 152 oblique to the base plane 150. The first orifice 148 is defined by a first wall 148 a that couples the first and second surfaces, 20 and 40, respectively, and the first orifice 148 extends along a first orifice axis 202 oblique with respect to the longitudinal axis 200. Although the orifice can be formed of a suitable cross-sectional area such as for example, square, rectangular, oval or circular, the preferred embodiments include generally circular orifices having a diameter about 300 microns, and more particularly, about 150 microns. The first orifice 148 can be formed by a suitable technique or a combination of such techniques, such as, for example, laser machining, reaming, punching, drilling, shaving, or coining. Preferably, the first orifice 148 can be formed by stamping and punch forming such that when a dimpling tool deforms the work piece 10, a plurality of planar surfaces oblique to a base plane 150 can be formed. One of the plurality of the planar surfaces can include first facet 143 a.
Thereafter, a second facet 143 b can be formed at the same time or within a short interval of time with the first facet 143 a. The second facet 143 b can be generally parallel to a second plane oblique 154 to the base plane 150 such that the orifices disposed on the second facet is oblique to the longitudinal axis 200. The second facet 143 b can also be oblique with respect to the first facet 143 a. Additional facets can also be formed for the orifice disc in a similar manner to provide for a dimple with more than two facets.
In order to quantify the advantages of the preferred embodiments with respect to metering orifice plate that utilizes straight or non-angled orifices prior to the formation of facets (i.e., a control case), comparisons were made with respect to preferred embodiments that utilize angled orifices prior to the formation of facets. The control case was a work piece that utilizes orifices extending perpendicular to the planar surfaces of the work piece, which is deformed to form a plurality of facets. The orifice disc of the control case was configured so that it provides a desired fuel spray-targeting pattern under controlled conditions. The test cases, on the other hand, utilize the preferred embodiments at various configurations such that these various configurations permit fuel spray targeting similar to the desired fuel spray targeting under the controlled conditions. That is, even though the physical geometry of each of the test cases was different, the fuel spray targeting of each of the test cases was required to be generally similar to that of the control case. And as used herein, spray targeting is defined as one of a bending spray angle or a splitting spray angle relative to the longitudinal axis 200 of a standardized fluid flowing through the fuel injector of the control case and the preferred embodiments at controlled operating conditions, such as, for example, fuel temperature, fuel pressure, flow rate and coil actuation duration.
An orifice disc 14 using perpendicular orifices prior to dimpling, i.e., a “pre-dimpled” disc, for the control case is shown in
The orifice disc 140 after dimpling, i.e., a “post-dimpled” orifice disc is shown for the control case in
Data of Control Case, First, Second, and Third Preferred Embodiments
The comparative analysis above is believed to illustrate the advantages of the present invention in allowing for at least a reduced sac volume, apex height “h”, “h/S” ratio, bending spray angle β and splitting angle λ while maintaining the same spray targeting of a control case that uses perpendicularly-oriented orifices in the pre-dimpled orifice disc. Furthermore, by comparisons with a control case, it can be seen that the preferred embodiments permit generally the same desired fuel spray targeting previously achievable with a control case yet with better fuel injector characteristics such as, for example, sac volume, lower material distortion or failure of the orifice disc during the manufacturing process. Moreover, it can be seen that the spray angle θ of each of the orifices is now a result of at least two angles (orifice angle α and at least one of the bending spray angle β and splitting angle λ) such that expanded ranges of bending and splitting angles can be manufactured without causing any reduction in structural integrity of the orifice disc 140 while also reducing the sac volume, the height of the apex and the amount of dimpling force or stress applied to the orifice disc that would otherwise not be achievable without utilization of the preferred embodiments.
Upon actuation of the magnetic actuator 134 to move the closure member to the actuated position, fuel is permitted to flow through the orifice disc in order to achieve a desired spray pattern similar to the control case. In particular, as shown in
The targeting of the fuel injector can also be performed by rotational adjustment of the orifice disc 140 relative to the longitudinal axis or by rotational adjustment of the housing relative to the orifice disk 140 so as to achieve a desired targeting configuration. A target can be placed on a virtual plane 180 disposed generally orthogonal to the longitudinal axis so that a suitable fluid spray from a fuel injector 100 can define a flow pattern with a plurality of different radii about the longitudinal axis. One of the radii (e.g., r1, r2, r3. . . rn) defining the flow pattern includes a maximum radius rmax that, when rotated about the longitudinal axis A—A, defines an imaginary circular area 186. The circular area 186 is larger than a portion covered by the flow pattern of fuel (e.g., fuel flow pattern such as FA1 or FA2). That is, the imaginary circular area 186 has uncovered portion 184 which is not impinged by fuel flow on the virtual plane spaced at the distance LT. Where the portion covered by the flow pattern is not a desired target portion, the flow pattern 182 can be oriented about the longitudinal axis A—A so as to adjust a targeting of the flow pattern 182 towards a different portion of the imaginary circular area 186 such as the non-covered portions 184. That is, where targeting of the flow pattern requires orientation of the metering orifices about the longitudinal axis, either the orifice disc or the fuel injector can be oriented with respect to each other. Also, the body 128 containing orifice disc can be rotated relative to the housing or a modular power group subassembly. Alternatively, the orifice disc 140 can be angularly fixed relative to a reference point on the body of the fuel injector. Upon installation into a fuel rail or manifold, the housing of the fuel injector can be rotated about the longitudinal axis to another reference point on the fuel rail or fuel injector cup (not shown) and then locked into position, thereby providing a desired targeting of the fuel flow pattern for the particular engine configuration. Subsequently, fuel injectors for this particular engine configuration can be orientated at the desired targeting configuration by one or a combination of the preceding procedures. And by re-orientating the flow pattern as needed for a specific engine configuration, as described above, a desired fuel spray targeting towards a specific portion of area with the imaginary circular area 186 defined by the maximum radius rmax can be achieved.
While the present invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims, and equivalents thereof.
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|U.S. Classification||239/5, 239/552, 239/533.12, 239/497, 239/596, 239/494, 239/585.5|
|International Classification||F02M51/06, F02M61/18, F02D1/06|
|Cooperative Classification||F02M61/1853, F02M51/06|
|Apr 30, 2004||AS||Assignment|
Owner name: SIEMENS VDO AUTOMOTIVE, INCORPORATED, MICHIGAN
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JOSEPH, J. MICHAEL;REEL/FRAME:015287/0476
Effective date: 20040427
|Jan 30, 2006||AS||Assignment|
Owner name: SIEMENS VDO AUTOMOTIVE CORPORATION, MICHIGAN
Free format text: CORRECTION OF ASSIGNEE NAME RECORDED REEL/FRAME 015287/0476;ASSIGNOR:JOSEPH, J. MICHAEL;REEL/FRAME:017497/0897
Effective date: 20060120
|Sep 30, 2010||FPAY||Fee payment|
Year of fee payment: 4
|Oct 2, 2014||FPAY||Fee payment|
Year of fee payment: 8
|Feb 12, 2015||AS||Assignment|
Owner name: CONTINENTAL AUTOMOTIVE SYSTEMS US, INC., MICHIGAN
Free format text: CHANGE OF NAME;ASSIGNOR:SIEMENS VDO AUTOMOTIVE CORPORATION;REEL/FRAME:034979/0865
Effective date: 20071203
|Feb 25, 2015||AS||Assignment|
Owner name: CONTINENTAL AUTOMOTIVE SYSTEMS, INC., MICHIGAN
Free format text: MERGER;ASSIGNOR:CONTINENTAL AUTOMOTIVE SYSTEMS US, INC.;REEL/FRAME:035091/0577
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